I know it's supposed to be a 33, but last night my range-o-meter was telling me I had 42 miles left, and that I've been averaging 11.8 mpg. So I figured I must have about 3 or 4 gallons in the tank right? (I know the computer calculates these numbers differently, but I don't think they'd be different by very much.)

Got to the gas station and it wouldn't take a drop over 25 gallons... I'm thinking a 33 gallon tank with 3 or 4 gallons in it should hold close to 30, right?

I can understand Ford leaving a little cushion in the calculations, but 5 gallons is quite a fudge factor.

I've noticed this several times now... very little range left, gas needle down right next to "E", and then instead of gulping down 29 or 30 gallons it quits at 25... which would be just right if it were a 28 gallon tank.

I rarely put more than 22 or 23 gallons in my "mini" Expedition. And the message center is hounding me to refuel. I doubt I've ever put 25 in the tank with the message center telling me I had 2 more miles to empty.

ISSUE
Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling.

ACTION
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Ask the customer the following questions.
1. Does the customer refill the fuel tank with the engine off?

a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply.

b. Yes - Go to Step 2.

NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75.

2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs?

a. Yes - Go to Step 3.

b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply.

3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange.

Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT : Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

I'll try to remember to see what my ODB2 fuel level reading shows when I get the 50 mile fuel warning. This is an analog reading and fluctuates wildly on the road, so I rarely look at it, but is steady when parked on level pavement. Reads out in percent full. It may or may not mirror the fuel level reading on the dash.

09/29/08
LONG WHEEL BASE (LWB) - FUEL GAUGE READS
BETWEEN 3/4 AND 7/8 WHEN FULL

FORD:
2007-2008 Expedition

LINCOLN:
2007-2008 Navigator

ISSUE
Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full.

ACTION
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE
1. Question the customer - yes/no.

a. Refueling event more than a 5 gallon fill?

b. Customer refilled with the engine off?

c. Customer refilled to 1 to 3 auto-shutoffs?

NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75.

If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full.
2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands.

a. If not okay, refer to WSM recommendations.

b. If okay, go to Step 3.

3. Follow Pinpoint Test A Section 413-01:

Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester.
a. If not, refer to WSM recommendations.

b. If okay, go to Step 4.

4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod?

6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange.

a. If blue pen mark is present, use the FDM as the replacement.

b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing.

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT : Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

You'd think ford would just have a re-flash to correct the fuel level problem for the EL's. Now that my vehicle is past the 36k warranty, I'd have to pay to have this fixed (unless someone can tell me otherwise). I too seem to only be able to put 25 gallons in an empty tank, or at least one that the lie-o-meter says has 0 miles to empty. I wondered if they program logic was any different from the regular lengths Expys that only hold like 28 gallons.

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